Method for protecting a muffler with polyester resin/fiberglass laminate

ABSTRACT

The invention disclosed herein is a method to prevent corrosion and deterioration by weather and environmental factors on mufflers by covering the mufflers with flexible moldable laminate shells. The flexible moldable laminate shells are composed of fiberglass reinforced plastic laminate impregnated with polyester resin. The flexible moldable laminate shells can be cut to size with scissors and molded to the muffler or any other object to be protected. After exposure to natural or artificial ultraviolet light, the flexible moldable laminate shells harden into an impermeable layer to protect the muffler from deterioration.

CROSS-REFERENCE TO RELATED APPLICATIONS

None

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

No part of this invention was the subject of federally sponsored research or development.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

None

REFERENCE TO A SEQUENCE LISTING

Not applicable.

BACKGROUND OF THE INVENTION

1. Field

The field of the invention disclosed herein is a cover for mufflers to protect the muffler from the corrosive effects of weather and the environment in which the muffler is employed.

2. Description of the Prior Art

Most fossil fuel powered engines produce a large amount of noise when operating. This noise can be obnoxious and harmful to those nearby. Various methods have been employed to lessen the noise produced by engines. The muffler is usually attached to the exhaust system of an engine in order to muffle or decrease the noise produced by the engine. Most of these muffler devices employ a tube, canister or other metal device which contains a baffle system inside the muffler to lessen the sound emanating from the engine. The baffle system inside the muffler may be constructed from metal, glass, fiber or other material depending on the application. The muffler is usually constructed from a metal such as aluminum which is partially resistant to the corrosive effects of the environment in which it operates. Exposure to water, dirt, and corrosive substances can damage or destroy the muffler rendering it useless. What is needed in the art is a muffler cover which is easy to install and resistant to the corrosive effects of the environment.

BRIEF DESCRIPTION OF THE INVENTION

The invention disclosed herein is a muffler cover which is easy to install and resistant to the corrosive effects of the environment. Specifically, the invention disclosed herein is a flexible moldable polyester resin/fiberglass laminate which is cured by exposure to UV light. The polyester laminate can be easily molded to cover virtually any shape of muffler. When the molding is complete, the laminate is exposed to either natural or artificial ultraviolet light for approximately 15 minutes. After this exposure to ultraviolet light, the polyester laminate hardens and forms an impermeable shell around the muffler. The polyester laminate protects the metal shell of the muffler from the corrosive effects of the environment.

BRIEF DESCRIPTION OF THE DRAWING/FIGURES

A better understanding of the invention disclosed herein may be had be examination of the attached drawing/figures.

FIG. 1 is a cutaway view showing the various layers of material used to cover a muffler.

FIG. 2 is a cross sectional view showing the various layers of material used to cover a muffler

FIG. 3 is a cross sectional view showing the various layers of material used to cover a muffler.

FIG. 4 is a view of the muffler covered by the invention disclosed herein.

DETAILED DESCRIPTION OF THE INVENTION

The method described herein for protecting mufflers is a flexible moldable shell which can be easily applied to the surface of the muffler. The flexible moldable laminate shell is constructed from fiberglass reinforced plastic laminate impregnated with a polyester resin that cures to a hard impenetrable shell when exposed to artificial or natural (sunlight) ultraviolet irradiation and is commercially available as SolarShell® (a registered trademark of Unitherm, Inc.). When uncured the flexible moldable laminate shells are soft sheets of material which may be cut to size with scissors and wrapped around virtually any muffler wherein it conforms to the shape of the structure. On exposure to UV light the shell cures in approximately 15 minutes forming a hard impenetrable shell around the muffler. The flexible moldable laminate shells can also be used to cover and protect a variety of industrial and residential applications such as repair of water pipe, repair of damage to the fiberglass bodies of cars and boats, protection of structures exposed to sea water, repair of leaking tanks and pipes, repair of gutters and many more.

As shown in FIG. 1, the flexible moldable laminate shells can be used to cover and protect a muffler. In one embodiment, a muffler 1 is first covered with a silencer 2 constructed from glass, stainless steel or other material compatible with the application which serves to further minimize noise. The silencer 2 is then covered with a layer of heat resistant insulation 3 constructed from glass, stainless steel or other heat resistant material which limits the amount of heat which escapes from the skin of the muffler 1 into the immediate surroundings. The top layer covering the muffler 1 is a layer of flexible moldable laminate shell 4 cut and molded to cover the surface of the muffler 1. After exposure to ultraviolet light, the flexible moldable laminate shell 4 forms a hard and impermeable barrier which protects the muffler 1, silencer 2 and insulation 3 from deterioration by weather and other environmental factors.

In another embodiment, as shown in FIG. 4, the muffler 1 is first covered with a layer of silencer 2, the level of which is appropriate for the intensity of noise produced by the muffler 1. Approximately 1 inch of heat resistant insulation 3 is than wrapped around the muffler 1 to cover both the muffler 1 and the layer of silencer material 2. Finally, a layer of flexible moldable laminate shell 4 is applied to a depth of approximately 0.13 inches to cover the entire surface of the muffler 1 which is wrapped in silencer 2 and heat resistant insulation 3. After 15 minutes of exposure to ultraviolet light, the layer of flexible moldable laminate shell 4 hardens to form an impenetrable layer. The method disclosed herein protects the layers of insulation 3, silencer 2 and the muffler 1 itself from the corrosive effects of weather and the environment.

In another embodiment of the invention disclosed herein, a muffler 1 can be covered with heat resistant insulation followed by an overlay of flexible moldable laminate shell 4 as shown in FIG. 2. The muffler 1 is first covered by a heat resistant insulating material 3 to lessen the amount of heat escaping into the environment from the muffler 1. The insulation 3 is then covered with a layer of flexible moldable laminate shell 4 which after exposure to ultraviolet light forms a hard, impermeable barrier. The method disclosed herein protects the insulation 3 and muffler 1 from the deleterious effects of weather and other environmental factors.

In another embodiment of the invention disclosed herein, the muffler 1 is first covered with silencer 2 and then covered with the flexible moldable laminate shell 4 as shown in FIG. 3. The muffler 1 is wrapped in silencer material 2 which is then covered with flexible moldable laminate shell 4 which after exposure to ultraviolet light forms a hard, impermeable barrier. The disclosed method protects the silencer 2 and muffler 1 from the deleterious effects of weather and other environmental factors.

The method disclosed herein is adaptable and may be used in a variety of applications to protect objects such as pipes, exposed surfaces on cars, boats, trailers, airplanes, and equipment from deterioration due to the effects of weather and the environment. These other embodiments are incorporated into this specification and as further limited by the appended claims. 

I claim:
 1. A method for protecting mufflers from deterioration by weather and environmental factors comprising steps for: covering the muffler with a layer of flexible moldable laminate shells made from a fiberglass reinforce plastic polyester resin; exposing said flexible moldable laminate shells to ultraviolet light for 15 minutes.
 2. A method for protecting mufflers from deterioration by weather and environmental factors comprising steps for: covering said muffler with a layer of silencer material; covering said silencer material layered onto said muffler with a layer of heat resistant insulation material; covering said insulation layered over said silencer material surrounding said muffler with a layer of flexible moldable laminate shells made from a fiberglass reinforced plastic impregnated with polyester resin; exposing said flexible moldable laminate shells to ultraviolet light for approximately 15 minutes.
 3. A method for protecting mufflers from deterioration by weather and environmental factors comprising steps for: covering said muffler with a layer of silencer material; covering said silencer material surrounding said muffler with a layer of flexible moldable laminate shells made from a fiberglass reinforced plastic impregnated with polyester resin; exposing said flexible moldable laminate shells to ultraviolet light for approximately 15 minutes.
 4. A method for protecting mufflers from deterioration by weather and environmental factors comprising steps for: covering said muffler with a layer of heat resistant insulation material; covering said heat resistant insulation material surrounding said muffler with a layer of flexible moldable laminate shells made from a fiberglass reinforced plastic impregnated with polyester resin; exposing said flexible moldable laminate shells to ultraviolet light for approximately 15 minutes. 